Expandable roof panel perimeter reinforcement

ABSTRACT

A vehicle roof frame includes an adhering structure having an adhesive carrier and an expanding structural adhesive coupled to at least a portion of an outer surface of the adhesive carrier. The expanding structural adhesive includes an installation state and a structural state, and the structural state has a larger volume than the installation state. The vehicle roof frame also includes a plurality of vehicle frame members that cooperate to form a frame joint and a joint cavity defined within the frame joint. The adhering structure is disposed within the joint cavity and the adhesive carrier and the expanding structural adhesive in the structural state substantially occupies the joint cavity and fixably couples the plurality of framing members such that the frame joint is free of supplemental mechanical connections proximate the joint cavity.

FIELD OF THE INVENTION

The present invention generally relates to a reinforcement for a vehicleframe joint, and more specifically, an expandable perimeterreinforcement for vehicle joints including roof panel joints.

BACKGROUND OF THE INVENTION

Typically, as vehicle frames are constructed, certain portions of theframe are difficult to reach or access in order to perform variouswelding functions to fully reinforce the vehicle frame. Theseaccessibility limitations can affect the efficiency in which a vehicleframe is constructed. Additionally, in various vehicles that requireenhanced reinforcement, the issues of accessibility of weldingmechanisms can be exacerbated, such that design choices for where toweld the various framing members can be very limited.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a vehicle roof frameincludes an adhering structure having an adhesive carrier and anexpanding structural adhesive coupled to at least a portion of an outersurface of the adhesive carrier. The expanding structural adhesiveincludes an installation state and a structural state, and thestructural state has a larger volume than the installation state. Thevehicle roof frame also includes a plurality of vehicle frame membersthat cooperate to form a frame joint and a frame joint defined withinthe frame joint. The adhering structure is disposed within the jointcavity and the adhesive carrier and the expanding structural adhesive inthe structural state substantially occupies the frame cavity and fixablycouples the plurality of frame members such that the frame joint is freeof supplemental mechanical connections proximate the joint cavity.

According to another aspect of the present invention, a vehicle jointframe includes a plurality of vehicle frame members at least partiallydefining a joint cavity, an adhesive carrier disposed in the jointcavity and an expanding structural adhesive disposed on an outer surfaceof the adhesive carrier and fixedly coupling the plurality of vehicleframe members. The adhesive carrier and the expanding structuraladhesive substantially fill the joint cavity.

According to another aspect of the present invention, a method offorming a vehicle frame joint includes the steps of forming an adheringstructure having an adhesive carrier and an expanding structuraladhesive disposed on at least a portion of an outer surface of theadhesive carrier, wherein the expanding structural adhesive is in acontracted state, placing a plurality of vehicle frame members tocooperatively form a frame joint and a joint cavity defined within theframe joint, placing the adhering structure within the joint cavity,wherein the adhering structure is capable of limited movement when theexpanding structural adhesive in is the contracted state and curing theadhesive layer. The method further includes the step of curing theexpanding structural adhesive to expand to a structural state andsubstantially fill the joint cavity and form a substantially fixedconnection between the plurality of vehicle frame members. Thesubstantially fixed connection is free of supplemental mechanicalconnections proximate the joint cavity.

These and other aspects, objects, and features of the present inventionwill be understood and appreciated by those skilled in the art uponstudying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a front side perspective view of a vehicle with an embodimentof the expandable reinforcement installed therein;

FIG. 2 is a top perspective view of a vehicle frame with an alternativeembodiment of the expandable reinforcement installed therein;

FIG. 3 is a cross-sectional view of the vehicle frame of FIG. 2 taken atline III-III with the expandable reinforcement in an installation state;

FIG. 4 is a cross-sectional view of the vehicle of FIG. 3 with theexpandable reinforcement in a structural state;

FIG. 5 is a perspective view of a vehicle frame with another alternativeembodiment of the expandable reinforcement installed therein; and

FIG. 6 is a schematic flow diagram illustrating a method for forming avehicle frame connection using an expandable reinforcement within avehicle frame.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

For purposes of description herein, the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the invention as oriented in FIG. 1. However, itis to be understood that the invention may assume various alternativeorientations, except where expressly specified to the contrary. It isalso to be understood that the specific devices and processesillustrated in the attached drawings, and described in the followingspecification are simply exemplary embodiments of the inventive conceptsdefined in the appended claims. Hence, specific dimensions and otherphysical characteristics relating to the embodiments disclosed hereinare not to be considered as limiting, unless the claims expressly stateotherwise.

As shown in FIGS. 1-4, reference numeral 10 generally refers to a frameinstalled within a vehicle, wherein the frame 10 includes an adheringstructure 14 having an adhesive carrier 16 and an expanding structuraladhesive 18 coupled to at least a portion of an outer surface 20 of theadhesive carrier 16. The expanding structural adhesive 18 includes acontracted installation state 22 and an expanded structural state 24,wherein the structural state 24 includes a larger volume of theinstallation state 22. A plurality of vehicle frame members 26 cooperateto form a frame joint 28 and a joint cavity 30 defined within the framejoint 28. The adhering structure 14 is disposed within the joint cavity30, wherein the adhesive carrier 16 and the expanding structuraladhesive 18, in the structural state 24, substantially occupies thejoint cavity 30 and fixedly couples the plurality of frame members 26such that the frame joint 28 is free of supplemental mechanicalconnections proximate the joint cavity 30.

Referring now to FIGS. 3 and 4, the adhesive carrier 16 can include anintegral attachment clip 40 that engages at least one of the vehicleframe members 26 of the frame 10 of the vehicle 12. In the variousembodiments, the attachment clip 40 includes a post 42 that extends fromthe outer surface 20 of the adhesive carrier 16 and extends to aretaining feature 44 disposed at the opposing end of the post 42. Atleast one of the plurality of frame members 26 includes a clipreceptacle 46 for receiving and securing the retaining feature 44 of theattachment clip 40. In this manner, the post 42 of the attachment clip40 is slidably engaged within the clip receptacle 46, such that theadhering structure 14 is allowed limited movement within the jointcavity 30 when the attachment clip 40 is secured within the clipreceptacle 46. The expanding structural adhesive 18 is in theinstallation state 22. In this manner, when the adhering structure 14 isdisposed within the joint cavity 30, the adhering structure 14 can beshifted and moved within the joint cavity 30 to ensure proper alignmentof the adhering structure 14 within the joint cavity 30.

In the various embodiments, it is also contemplated that the attachmentclip 40 is integrally formed as part of the adhesive carrier 16. It isalso contemplated that the attachment clip 40 can be a separate piecethat is attached to the adhesive carrier 16 by welding, mechanicallyfastening, adhering or otherwise connecting the attachment clip 40 to apredetermined portion of the adhesive carrier 16. It is furthercontemplated that the retaining feature 44 and the post 42 can beintegrally formed. In such an embodiment, portions of the retainingfeature 44 can be substantially flexible to allow the retaining feature44 to pass through the clip receptacle 46 and be substantially retainedtherein. The retaining feature 44 and the clip receptacle 46 can also becooperatively formed such that the retaining feature 44 and the clipreceptacle 46 include tabs, protrusions, recesses or other similarforms. These forms allow the retaining feature 44 to pass through theclip receptacle 46 in a predetermined configuration, but not be removedwhen the adhering structure 14 is placed in the final position withinthe joint cavity 30. In various embodiments, it is contemplated thatwhere the attachment clip 40 is a separate piece that can be attached tothe adhesive carrier 16, the attachment clip 40 can be inserted throughthe clip receptacle 46, opposite the adhesive carrier 16, and attachedto the adhesive carrier 16 positioned in the joint cavity 30. In thismanner, the connection of the attachment clip 40, through the clipreceptacle 46, and to the adhesive carrier 16 serves to substantiallyposition the adhering structure 14 in the predetermined position beforebeing cured.

Referring again to FIGS. 3 and 4, as the expanding structural adhesive18 is cured, as will be described more fully below, the expansion of theexpanding structural adhesive 18 moves the adhering structure 14 withinthe joint cavity 30. As the adhering structure 14 moves within the jointcavity 30 during the expansion of the expanding structural adhesive 18,the engagement between the attachment clip 40 and the clip receptacle 46of the vehicle frame 10 is configured to guide the movement of theadhering structure 14 within the joint cavity 30 to substantially insureproper alignment of the adhering structure 14 within the joint cavity30. Accordingly, the various frame members 26 of the vehicle frame 10are joined together through the use of the adhering structure 14 withoutthe need for individual welding between the members at points within thejoint cavity 30, which may be difficult for various welding apparatus toreach. It is contemplated that exterior portions 60 of the various framemembers 26 can be welded through spot welding, laser welding, and otherwelding operations. However, in certain vehicles, it is necessary toprovide additional structural reinforcement through structuralconnections that are disposed on interior portions 62 and exteriorportions 60 of the various frame joints 28. In this manner, the adheringstructure 14 substantially minimizes the need for complex weldingoperations and mechanisms in order to provide this additionalreinforcement upon interior portions 62 of the frame joint 28 proximatethe joint cavity 30. In this manner, the adhering structure 14 beingplaced within the joint cavity 30 and the expanding structural adhesive18 being bonded to the frame joint 28 can eliminate the need forsupplemental mechanical connections within the joint cavity 30. Suchsupplemental mechanical connections can include, but are not limited to,welds, nut and bolts connections, rivets, screws, hooks, pins,combinations thereof, and other similar mechanical connections.

Referring again to FIGS. 3 and 4, the expanding structural adhesive 18is cured during one of several curing processes that can include, butare not limited to, an electrocoat cure for various portions of thevehicle frame members 26, an independent curing cycle dedicated to theexpanding structural adhesive 18, or other curing period for portions ofthe vehicle frame 10. It is also contemplated that the cure for theexpanding structural adhesive 18 is included as a portion of amulti-part cure of one or more portions of the vehicle frame 10. As thecure takes place, the expanding structural adhesive 18 is exposed toheat, wherein the heat serves to activate the expanding structuraladhesive 18. Once activated, the expanding structural adhesive 18increases in volume and changes to have adhesive properties. Theadhesive properties of the expanding structural adhesive 18 experiencedduring the cure allow the expanding structural adhesive 18 to fill thejoint cavity 30 and engage and adhere to the inner surface 70 of thejoint cavity 30.

Referring now to FIGS. 2-5, it is contemplated that the adheringstructure 14 can be disposed at localized areas within the vehicle frame10, such that minimally sized adhering structures 14 are disposed atspecific frame joints 28 of the frame 10 of the vehicle 12. It iscontemplated that the embodiments of the adhering structure 14 can beused in areas within certain linear portions of the frame 10 of thevehicle 12, such as linear members of the frame 10 that extend betweencertain frame joints 28. By way of explanation, and not limitation, theadhering structure 14 can be positioned upon or within the frame 10 atlinear portions extending between two frame joints 28 of the roof frame82. In various alternate embodiments, it is contemplated that theadhering structure 14 can extend substantially around a perimeter 80 ofthe frame 10 of the vehicle 12, such as around the perimeter 80 of theroof frame 82 of the vehicle 12. Regardless of the size andconfiguration of the adhering structure 14, the expanding structuraladhesive 18, when in the structural state 24, is configured tosubstantially fill the interstitial space 84 within the joint cavity 30that is defined by the plurality of frame members 26 and the adhesivecarrier 16.

In the various embodiments, the adhesive carrier 16 of the adheringstructure 14 is sized such that when the expanding structural adhesive18 is disposed on the outer surface 20 of the adhesive carrier 16, andthe expanding structural adhesive 18 is in the contracted state, theadhering structure 14 is at least slightly smaller than the interstitialspace 84 defined between the inner surface 70 of the joint cavity 30 andthe adhesive carrier 16. The adhesive carrier 16 is further sized suchthat the expanding structural adhesive 18, when cured, is configured toexpand a sufficient distance away from the adhesive carrier 16 tosubstantially fill the interstitial space 84 of the joint cavity 30between the adhesive carrier 16 and the various vehicle frame members 26that define the frame joint 28 of the frame 10. The size of the adhesivecarrier 16 and the amount and/or thickness of the expanding structuraladhesive 18 can vary depending on several factors that include, but arenot limited to, the configuration of the frame joint 28 and the jointcavity 30, the type of expanding structural adhesive 18, the temperatureand duration of the cure, the desired strength of the frame joint 28,the material of the frame members 26 and the adhesive carrier 16, amongothers.

Referring again to FIGS. 1-5, the expanding structural adhesive 18 caninclude various bonding agents that can include, but are not limited to,epoxy, acrylic, urethane, anaerobic adhesives, multi-part adhesives,film-type adhesives, fluid-type adhesives and other various adhesivesthat expand to form a structural bond. It is contemplated that theexpanding structural adhesive 18 is bonded to various frame members 26that can include, but are not limited to, roof frame members, floorframe members, pillar members, and various other frame members withinthe vehicle 12 and frame 10. These various frame members 26 can be madeof various materials that can include, but are not limited to, aluminum,aluminum alloys, composite, steel, combinations thereof, and othervarious vehicle framing materials 26. The adhesive carrier 16 of theadhering structure 14 that receives the expanding structural adhesive 18in the installation state 22 can be made of various materials that caninclude, but are not limited to, aluminum, aluminum alloys, steel, steelalloys, composite, plastic, rubber, one or more polymers and othervarious substantially rigid materials. It is further contemplated thatthe adhesive carrier 16 can be an extrudable material wherein theadhesive carrier 16 can be extruded to the exact dimensions necessaryfor installation within the joint cavity 30. It is also contemplatedthat the adhesive carrier 16 and the expanding structural adhesive 18can be a co-extruded system wherein the adhesive carrier 16 and theexpanding structural adhesive 18 are extruded as a single unit andsubstantially dimensioned for installations in the various applicationswithin the vehicle frame 10.

As illustrated in FIGS. 1-5, it is contemplated that the adheringstructure 14 can be used to form a structural attachment between certainbody panels 100, retain body panels 100 to portions of the frame 10, orother similar structural connections within the vehicle 12.Additionally, while the adhering structure 14 can be used in locationsof the vehicle 12 that may be difficult for placing mechanical fastenersor welds, the adhering structure 14 can also be used instead of or inaddition to welds or mechanical fasteners, even in conditions whereaccessing the connection point is not difficult.

Having described the general structure and configuration of the adheringstructure 14, including the adhesive carrier 16 and the expandingstructural adhesive 18, a method 600 for forming a vehicle frameconnection is described herein for incorporating the adhering structure14 within the frame 10 of a vehicle frame connection for providing astructural connection between various frame members 26 within a jointcavity 30 defined by the connection between the various frame members26. According to the method 600, one step includes forming an adheringstructure 14 having an adhesive carrier 16 and an expanding structuraladhesive 18 disposed on at least a portion of an outer surface 20 of theadhesive carrier 16, and wherein the expanding structural adhesive 18 isin a contracted state (step 602). Another step in the method includesplacing a plurality of vehicle frame members 26 in a pre-determinedconfiguration to cooperatively form a frame joint 28 and a joint cavity30 defined within the frame joint 28 (step 604). The adhering structure14 is then placed within the joint cavity 30, wherein the adheringstructure 14 is capable of limited movement within the joint cavity 30when the expanding structural adhesive 18 is in the contracted state(step 606).

Referring again to FIG. 6, according to various embodiments of themethod, the adhesive carrier 16 can include an integral attachment clip40 that engages at least one of the plurality of vehicle frame members26. In such embodiments, the attachment clip 40 includes a post 42 thatextends from a surface of the adhesive carrier 16 and includes aretaining feature 44 at the opposing end of the post 42. As the adheringstructure 14 is disposed within the joint cavity 30, the retainingfeature 44 is disposed within a receptacle defined within one or more ofthe vehicle frame members 26, wherein the retaining feature 44 issubstantially secured within the clip receptacle 46 (step 608). Once theadhering structure 14 is disposed within the joint cavity 30, theadhering structure 14 is configured such that the post 42 is affordedsome limited movement within the clip receptacle 46. During performanceof the method, the adhering structure 14 can be manipulated within thejoint cavity 30 to insure proper alignment of the adhering structure 14within the cavity (step 610). Additionally, the limited movementafforded to the adhering structure 14 within the cavity allows theadhering structure 14 to move during curing of the expanding structuraladhesive 18, such that the expanding structural adhesive 18 can beevenly adhered throughout the inner surface 70 of the joint cavity 30.

Referring again to FIG. 6, another step in the method 600 includescuring the expanding structural adhesive 18, such that the expandingstructural adhesive 18 expands to a structural state 24 (step 612). Whenin the structural state 24, the expanding structural adhesive 18substantially fills the joint cavity 30 and forms a substantially fixedconnection between the plurality of vehicle frame members 26. In thismanner, the plurality of vehicle frame members 26 can be attached at thejoint cavity 30 without the need for additional mechanical connectionsor welds within the joint cavity 30.

It is to be understood that variations and modifications can be made onthe aforementioned structure without departing from the concepts of thepresent invention, and further it is to be understood that such conceptsare intended to be covered by the following claims unless these claimsby their language expressly state otherwise.

What is claimed is:
 1. A vehicle roof frame comprising: an adheringstructure having an adhesive carrier and an expanding structuraladhesive coupled to at least a portion of an outer surface of theadhesive carrier, wherein the expanding structural adhesive includes aninstallation state and a structural state, the structural state having alarger volume than the installation state; and a plurality of roof framemembers that cooperate to form a frame joint and a joint cavity definedwithin the frame joint, wherein the adhering structure is disposedwithin the joint cavity and wherein the adhesive carrier and theexpanding structural adhesive in the structural state substantiallyoccupies the joint cavity and fixably couples the plurality of framemembers such that the joint cavity is free of supplemental mechanicalconnections.
 2. The vehicle roof frame of claim 1, wherein the expandingstructural adhesive is co-extruded with the adhesive carrier.
 3. Thevehicle roof frame of claim 2, wherein the adhering structure extendssubstantially around a perimeter of the vehicle roof frame.
 4. Thevehicle roof frame of claim 2, wherein the adhesive carrier includes anintegral attachment clip that engages at least one of the plurality ofroof frame members.
 5. The vehicle roof frame of claim 4, wherein theattachment clip includes a post and a retaining feature, and wherein atleast one of the plurality of roof frame members includes a clipreceptacle for receiving and securing the retaining feature of theattachment clip, wherein the post of the attachment clip is slidablyengaged with the clip receptacle, wherein the adhering structure isallowed limited movement within the joint cavity when the attachmentclip is secured within the clip receptacle and the expanding structuraladhesive is in the installation state.
 6. A vehicle joint framecomprising: a plurality of vehicle frame members at least partiallydefining a joint cavity; an adhesive carrier disposed in the jointcavity; and an expanding structural adhesive disposed on an outersurface of the adhesive carrier and fixedly coupling the plurality ofvehicle frame members, the adhesive carrier and the expanding structuraladhesive substantially filling the joint cavity.
 7. The vehicle jointframe of claim 6, wherein the expanding structural adhesive isco-extruded with the adhesive carrier.
 8. The vehicle joint frame ofclaim 7, wherein the adhesive carrier and the expanding structuraladhesive extends substantially around a perimeter of a vehicle frame. 9.The vehicle joint frame of claim 7, wherein the adhesive carrierincludes an integral attachment clip that engages at least one of theplurality of vehicle frame members.
 10. The vehicle joint frame of claim9, wherein the expanding structural adhesive includes an installationstate and a structural state, wherein the structural state has a greatervolume than the installation state.
 11. The vehicle joint frame of claim10, wherein the structural state of the expanding structural adhesivesubstantially fills an interstitial space in the joint cavity definedbetween the plurality of frame members and the adhesive carrier.
 12. Thevehicle joint frame of claim 10, wherein the attachment clip includes apost and a retaining feature, and wherein one of the plurality ofvehicle frame members includes a clip receptacle for receiving andsecuring the retaining feature of the attachment clip, wherein the postof the attachment clip is slidably engaged with the clip receptacle,wherein the adhesive carrier is allowed limited movement within thejoint cavity when the attachment clip is secured within the clipreceptacle and the expanding structural adhesive is in the installationstate.
 13. The vehicle joint frame of claim 6, wherein the plurality ofvehicle frame members, the adhesive carrier and the expanding structuraladhesive in the structural state defines the frame joint that is free ofsupplemental mechanical connections proximate the joint cavity.
 14. Amethod of forming a vehicle frame joint comprising the steps of: formingan adhering structure having an adhesive carrier and an expandingstructural adhesive disposed on at least a portion of an outer surfaceof the adhesive carrier, wherein the expanding structural adhesive is ina contracted state; placing a plurality of vehicle frame members tocooperatively form a frame joint and a joint cavity defined within theframe joint; placing the adhering structure within the joint cavity,wherein the adhering structure is capable of limited movement when theexpanding structural adhesive in is the contracted state; and curing theexpanding structural adhesive, wherein the expanding structural adhesiveexpands to a structural state, wherein the expanding structural adhesivesubstantially fills the joint cavity and forms a substantially fixedconnection between the plurality of vehicle frame members, and whereinthe substantially fixed connection is free of supplemental mechanicalconnections.
 15. The method of claim 14, wherein the step of forming theadhering structure includes co-extruding the adhesive carrier and theexpanding structural adhesive.
 16. The method of claim 14, wherein theadhesive carrier includes an integral attachment clip that engages atleast one of the plurality of vehicle frame members.
 17. The method ofclaim 16, wherein the attachment clip includes a post and a retainingfeature, and wherein one of the plurality of vehicle frame membersincludes a clip receptacle for receiving and securing the retainingfeature of the attachment clip, wherein the post of the attachment clipis slidably engaged with the clip receptacle, wherein the adhesivecarrier is allowed limited movement within the cavity when theattachment clip is secured within the clip receptacle and the expandingstructural adhesive is in the installation state.
 18. The method ofclaim 14, wherein the frame joint is a connection between a vehicle roofframe and a vehicle pillar.
 19. The method of claim 18, wherein theadhering structure extends substantially around a perimeter of thevehicle roof frame.
 20. The method of claim 19, wherein the adheringstructure is adapted to form a substantially fixed connection betweeneach vehicle pillar and the vehicle roof frame.